Column forming apparatus and methods

ABSTRACT

A column forming apparatus wherein concrete is poured into a cavity of the apparatus to form a column for a wall. Embodiments include forming the column both off-site and on-site. Other embodiments include forming a columnless wall. In one embodiment of a column molding apparatus, first and second forming pieces and first and second blocking members can be used to form a column of predetermined shape with the blocking members leaving indentations in the formed column.

This application claims the benefit of U.S. Application 60/966,721, filed Aug. 28, 2007, the entire contents of which is expressly incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to apparatus and methods for forming for walls and constructing columnless walls.

SUMMARY OF THE INVENTION

A concrete wall is constructed by aligning pre-fabricated wall panels supported by columns at the panel ends. A wall can be configured so that the wall panels are supported solely by the columns and column footings. One embodiment of a wall includes a trench filled with concrete below the wall panels in order to protect against erosion and digging animals.

Using embodiments of a column-forming apparatus, columns can be constructed at a site away from the wall location or each column can be constructed in its designated onsite location. Embodiments of a column-forming apparatus can include a mold apparatus having several pieces and clamps to hold the pieces in position. In one embodiment, the column form includes light weight pieces including foam elements supporting internal liners that create the pattern, shape and texture of the exterior of the column to be formed. Block out parts create slots, holes or voids for interacting with the fence panels supported between the columns. In one embodiment, the column mold includes a plug which creates a hole through the center of the column so that the column can be secured to a footing with protruding rebar.

In other embodiments, a wall is constructed by first positioning adjacent wall panels and then forming columns between the panels by pouring concrete into a column mold between the panels. A column footing is constructed which may support the column mold and the ends of the wall panels. Wall panel supports are used to hold the wall panels in the proper position until the column is complete. The column mold is configured to incorporate the panel ends and is held in position by clamps. Rebar can be included in the column footing so that it extends upward into the column mold as to be incorporated into the column.

In still other embodiments, a columnless wall is constructed by configuring a wall panel joint so that the adjacent panels are closely positioned and a column is not necessary to secure them. In one embodiment, pieces of rebar extend through the panel ends and downward into an excavation below the panel joint. The wall panel ends can also include a tongue and grove in order to improve privacy and add strength to the joint. Wall panel supports are used to hold the wall panels in position until the footings are poured and the panel ends are secure.

In other embodiments of the columnless walls, steel pipes set in footings interlock with profiled grooves formed in the opposing ends of the opposed concrete wall panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective exploded view of an embodiment of a column manufacturing apparatus.

FIG. 2 is a perspective view of an embodiment of an assembled column manufacturing apparatus.

FIG. 3 is a top view of an embodiment of an assembled column manufacturing apparatus.

FIG. 4 is a side view of an embodiment of a manufactured column installed between two wall panels.

FIG. 5 is a perspective view of an embodiment of a pour in place column mold installed between two wall panels.

FIG. 6 is a top view of a pour in place column mold installed between two wall panels.

FIG. 7 is a perspective view of an embodiment of a clamp assembly used to hold a mold in place.

FIG. 8 is a perspective view of pour in place wall panel mold with a clamp installed at the bottom.

FIG. 9 is a side view of an embodiment of a pour-in-place column constructed between two wall panels.

FIG. 10 is a perspective view of an embodiment of a panel support.

FIG. 11 is a perspective view of an embodiment of a panel supports holding wall panels in place as a pour-in-place column is constructed.

FIG. 12 is a side view of an embodiment of a columnless wall joint with a footing.

FIG. 13 depicts an embodiment of a coupling used to attach rebar.

FIG. 14 is a top view of an embodiment of wall panels with a tongue and groove configuration.

FIG. 15 is a perspective view of an embodiment of wall panels with a tongue and groove configuration.

FIG. 16 is a perspective view of an embodiment of a trench between two column footing excavations.

FIG. 17 is a perspective view of an embodiment of a continuous line of concrete and column footings.

FIG. 18 is a side view of an embodiment of a column cap with installed lifting devices.

FIG. 19 is a perspective view of an embodiment of a column cap with installed lifting devices.

FIG. 20 is a perspective view of another embodiment of a pour-in-place column mold.

FIG. 21 is a side view of the embodiment of FIG. 20.

FIG. 22 is an enlarged detailed perspective view of the upper end of the embodiment of FIG. 20.

FIG. 23 is an exploded view of the various parts of the embodiment of FIG. 20.

FIG. 24( a), 24(b), 24(c), 24(d) and 24(e) are perspective and end views of different column shapes made from the embodiments of FIGS. 20-23.

DETAILED DESCRIPTION Column Manufacturing

One embodiment of the column manufacturing apparatus and forming process includes, as shown in the embodiment illustrated in FIGS. 1-3, a mold 500 having two side pieces 510 and two block out pieces 515. The mold pieces can be held together by external clamps 520, 521 placed at various locations in order to contain pieces 510, 515 against the high pressures exerted by the poured liquid concrete used to form the columns. The two block out pieces 515 leave vertical recesses in the concrete column into which the ends of the wall panels can fit. The mold can also include a plug 525 placed in the center of the mold. Plug 525 is removed after the concrete has solidified to form a long hole 550 through the length of the column. Steel rebar 530 and mesh kits 535 can also be placed in the mold before the concrete is poured in order to provide the column with added strength. In one embodiment, 4 pieces of long rebar 530 are placed vertically within the mold and become integrated into the finished column. During construction of the column, the bottom of its manufacturing mold 500 may be supported on a surface such as a rubber mat, hard ground, or solid concrete.

After the concrete poured into the mold 500 has set for the requisite time, the clamps are disassembled and the mold removed. The resulting manufactured concrete columns 560 can then be transported to the wall site and, as shown in FIG. 4, installed at predetermined locations along the predetermined path of the desired fence.

In one embodiment, the manufactured fence posts can be initially installed at the desired location after which the individual concrete wall panels 400 are lowered between the installed columns by a crane (see, e.g., the crane shown in FIG. 15 of pending U.S. application Ser. No. 12/138,237, filed Jun. 12, 2008).

In another embodiment, the concrete wall panels 400 are temporarily braced in a vertical position as described below. The manufactured columns are then lowered between juxtaposed ends of respective panels.

Advantageously, the manufactured columns 560 and the ends of each panel 400 rest upon a column footing 540 which is generally an excavation filled with concrete. The column footing can have pieces of rebar 545 protruding upwardly which fit within the hole 550 in the center of the column by plug. When positioned correctly, the center hole 550 in the column can be filed with liquid concrete in order to permanently secure the column in place.

In wall construction, the manufactured columns can be advantageously configured so that the shape of the panel ends corresponds with the shape of the recesses in the columns. The wall panels 400 can be constructed using the process and apparatus described in pending U.S. application Ser. No. 12/138,237, filed Jun. 12, 2008. The process and apparatus described in this pending U.S. Application allow the wall panels to be constructed having predetermined thickness and shape so that the manufactured columns and panels can be interlocked to form a wall.

Pour-in-Place Columns

A pour-in-place apparatus and methods can be used to construct columns in situ as part of a wall under construction wherein the concrete panels 400 of the wall are already positioned, as shown in FIGS. 5-8. As described below and shown in FIGS. 10 and 11 a, free-standing panel supports 700 are used to correctly position the wall panels while the columns between the panels are constructed. A mold apparatus 600 having two side pieces 610, 611 can be used to form the poured concrete in a desired column shape. The side pieces 610, 611 are placed on both sides of the ends of juxtaposed positioned wall panels 400 so that the ends of the panels extend into the mold and shape the sides of the column. Pieces of cardboard 615 or other sturdy material may be folded around the ends of the panels in order to both protect the concrete from leaking out, and to isolate the newly poured concrete from the wall panel 400. Placing material between the wall panel 400 and the column can also facilitate the removal of broken or damaged wall panels replacement thereof at any time after construction of the wall. Excess cardboard may be cut away after construction and chinking material may be placed in any voids between the wall panel and the column.

The mold apparatus can be tightened around the wall panel ends using clamps 620 and 625 or braces at different locations on the side pieces. The clamp 620 at the top and clamp 625 at the bottom shown in FIG. 8 may be sufficient, but other braces between the ground and side pieces 610, 611 can be added for additional support. The bracing jigs 700 described below, for example, can be used for this purpose, with the diagonal members 715, 715A abutted between the ground and the side pieces 610, 611. The bottom clamp 625 is advantageously positioned so that it extends under the wall panels in order to hold both side pieces 610, 611 together during the pouring and curing of the concrete. The clamps 620, 625 and braces support the side pieces 610, 611 of the mold so that they can contain the very high pressures exerted when liquid concrete is poured into the mold apparatus 600.

The column mold pieces 610, 611 are typically set upon a column footing 540 which, as shown in FIG. 9, can be an excavation filled with concrete. Pieces of rebar 630 can be incorporated into the footing so that rebar extends upward into the column mold, and thereby incorporated into the pour-in place column when the mold apparatus 600 is filled with concrete. Thus in the embodiment of FIG. 9, the mold 600 and the ends of the concrete wall panels 400 rest on the column footing 540 as the column is constructed. The wall panels 400 may be constructed and shaped using the apparatus and methods described in pending U.S. application Ser. No. 12/138,237.

Another embodiment of a column forming apparatus and methods is illustrated in FIGS. 20-24 a, b, c, d and e. This embodiment can be used to construct columns for later erection on-site or in situ at the desired permanent location. The parts of this embodiment include straps 1700, outer forming members 1710, 1720, blockout members 1730, 1740 and liners 1750, 1760.

Straps 1700 are used to hold the parts together in the configuration shown. These straps will typically be made of metal, plastic or fabric or strength sufficient to contain the pressure exerted by the concrete where it is poured into one end of the open cavity 1770. This cavity is formed by external faces of the liners 1750, 1760 and blockout members 1730, 1740. While four straps 1700 are shown, it will be apparent that fewer or greater number of straps can be employed depending on the size and length of the overall molding apparatus.

The outer forming halves 1710, 1720 are typically made out of foam either hotwire cut, poured, sprayed or machined into shape. By way of specific example, foam having a 3 lb. density is suitable. The foam will be coated with a protective and semi-structural coating. The coating can be either a polyurea blend, plastic, or fiberglass or like product. The two halves have shaped into them locking grooves 1780 and slots 1790 (best shown in FIG. 22) that act to hold other pieces of the column form in place.

The blockout members 1730, 1740 provide indentations in the finished molded columns which can interact with other fencing products, such as fence panels made from, for example, concrete, vinyl, wood, block, and brick. These blockouts can be made into a variety of shapes so that the finished concrete column will have all kinds of slots, holes or voids where other fencing products can then be plugged, placed, mounted into position. Exemplary examples of finished columns 2000, 2010, 2020, 2030, and 2040 are illustrated in FIGS. 24 a-e. Other uses of the indentations are hold mounting plates made of steel whereby gates, posts or hinges can then be welded onto these plates after the form is removed. Blockout members 1730, 1740 advantageously include some type of tongue-and-groove system as shown at 1800 that will cause them to align with the outer halves 1710, 1720 and hold the blockout members 1730, 1740 in their correct position.

The liners 1750, 1760 can be made of plastic, fiberglass or rubber material. These materials will typically be produced from a master mold (rock pattern, tapered column shape, sand texture, etc.) thus creating a texture and shape within the mold to reproduce a precise texture and shape on the surface of the molded columns. Each of the ends of the liners advantageously have a tongue 1810 having a wedge or other locking shape that when placed into the mold and the mold is clamped together using the outer straps 1700, the liner will be and held into position by the shape of the wedge in the edge of the liner, advantageously eliminating the need for other devices such as screws or snaps to hold the liner in place. This wedge shape will also aid in sealing the form when it is closed so that wet concrete will not leak out of the form during the pouring process.

The column forming system of FIGS. 20-24 a, b, c, d and e is to provide the user of the system an easy and convenient way of forming a concrete column. The column can be made out of light weight material like foam so that it can be carried into a homeowners back yard, assembled very quickly, with concrete being poured into it, right at the location to where the column needs to be. When the straps 700 are removed, the form can be removed leaving the column in its exact resting place with a desired texture and/or shape.

Use of a foam or similar material for the forms 1710, 1720 allows producing all kinds of concrete column shapes including but not limited to square, rectangular, tapering and potbellied using a cylindrical; shaped exterior form. The various pressures from the concrete (or inside of the form) are transferred to a consistent cylindrical shape that can easily be secured by the strapping system. The foam fills in all of the space in between the two shapes and transfers even pressure to the outside surface where the metal straps contain the pressure pressers produced by the wet concrete.

The form 1750, 1760 can be made in various heights to produce various heights of columns anywhere from 1 foot to 8 feet or it can be made in one height such as 7 feet but then only filled to the height of the desired column. The radius of the outside of the form will vary depending on the size of the column being produced on the inside of the form. A typical diameter will be in the range of from 16 inches up to 6 feet, but even smaller or larger member can also be produced.

Another embodiment of the molding apparatus shown in FIGS. 20-23 can be constructed wherein separate liners 759, 760 are not utilized. Instead, the interior surfaces of the foam pieces 1710, 1720 can be coated with a finish surface that serves to create a desired surface on the face of the molded columns.

Although the illustrated apparatus of FIGS. 20-23 uses opposing halves 1710, 1720 of foam with each forming one-half of the exterior surface of the molded column, additional embodiments can include three or more forming members, secured together so that each forms a greater or lesser portion of the exterior surface.

The columns formed by the pour-in-place molding system of FIGS. 20-23 will typically further incorporate rebar positioned within the mold cavity 1770 before concrete is poured. In one embodiment, the rebar is already in place in a column footing, in the manner shown in FIG. 4. Alternatively, the column footing can be constructed at the same time the column is formed by setting the mold over an open footing hole, placing rebar into both the ground hole and cavity 770, after which concrete is poured through the cavity 1770 first into the footing hole in the ground followed by continued flow of concrete until the mold cavity 1770 is filled with concrete surrounding the rebar.

Panel Supports

Free-standing panel supports 700 are advantageously used to hold wall panels 400 in a desired position. In one embodiment shown in FIGS. 10 and 11, these panel supports can be strong enough to both lift and hold a panel off of the ground and at the same location and in the same position at which the panel will remain in the finished wall. The panel supports may also be adjustable so that the panel's vertical and horizontal position can be adjusted while it is being supported by the panel supports. In one embodiment as shown in FIGS. 10 and 11, a turn-buckle panel bracing jig 700 can be used for as the free-standing panel support convenient adjusting of the panel position.

The bracing jig 700 can include, as shown in the embodiment of FIGS. 10 and 11, a diagonal member 715 which is staked into the ground at one end 718 and supports the wall panel 400 vertically. A second L-shaped piece 720 fits snuggly against the side of the wall 400 and is bent so that it extends under the wall panel 400 and to the other side. On the other side, a similar straight piece 725 can be attached to the L-shaped piece 720 to form a brace along the entire bottom portion of the wall panel 400. A second diagonal member jig 700A supports the opposite side of the wall panel 400 so that the wall panel is supported on both sides.

In the embodiment shown, a turn-buckle apparatus 710, 710A respectively attaches the diagonal portion of the support 715, 715A to the L-shaped member 720 and member 725 so that the position of the wall panel can be easily adjusted. Thus, as the turn-buckles 710, 710A are turned, the overall length of the diagonal support is either lengthened or shortened. If both supports are lengthened, then the wall panel is moved upward and if they are shortened, then the wall panel is lowered. If the support on one side is lengthened and the support on the other side is shortened, then the wall will be moved to a different angle with respect to ground. The angle at which the fence panel 400 is set can be precisely adjusted using each of the turnbuckles 710, 710A. While the wall panels will typically be set vertically with a 90° angle with respect to a horizontal plane, it will be apparent that the respective jigs 700, 700A can be set for inclining the wall panel 400 an angle other than 90° for aesthetic or other reasons.

The bracing jigs are designed and constructed so that the panels 400 will not move unless the turnbuckles are intentionally turned. Thus, members 715, 720, 725 from sheet steel of requisite thickness, typically ⅛″ to ¼″.

Columnless Walls

FIGS. 12, 13, 14 and 15 depict embodiments of a columnless wall. An embodiment of a columnless wall joint includes a column footing 740 at each end of a wall panel 750 and also include a continuous concrete-filed trench 785 (shown in FIG. 17) beneath the concrete wall panels 750. In this embodiment of a columnless wall, there is no column formed at the joint where the two ends of the panels 400 meet. Instead, rebar 760 is advantageously embedded vertically in the ends of the panels 750 when the panels 750 are originally molded from concrete.

In another embodiment, two larger pieces of rebar are embedded in each panel end instead of four. Reinforcement rebar corresponding to the rebar extending from the panel end may also be placed in the excavation and driven into the ground below the excavation.

In the embodiment shown in FIGS. 12 and 13, each panel is molded with pieces of rebar 760 extending from the bottom used which are then placed within the excavation at the wall joint. In the embodiment shown in FIG. 12, the bottom ends of four rebar 760 terminate in threaded fittings 765. One end of each fitting 765 can be permanently attached to a piece of threaded rebar 760 while the opposite end of each fitting 765 is exposed at the bottom of a completed panel section. These exposed fittings provide threaded openings into which threaded ends of rebar footing 775 can be affixed in the field as the wall panel 750 is lowered into place by a crane so that a continuous rebar members comprising members 760, 765 and 775 extend from proximate the top of panel 750 to proximate the bottom of the excavation 740. When the wall panels 750 are in the proper position with the rebar 775 extending into the excavation 740, concrete is poured into the excavation forming a footing 540A to secure the panels.

During columnless wall construction, the wall panels are advantageously held in the proper position by panel supports 700 as discussed above. The panel supports support the wall panel until the poured footing is secure.

Another embodiment of the columnless walls is shown in FIGS. 14 and 15 where each molded concrete panel 770 has a molded tongue 771 at one end of the panel and a corresponding molded groove 772 at the other end of the panel. This tongue and groove profile serves to both secure the panels and provide privacy.

Another embodiment of this columnless wall (not shown) includes a plate spanning across the joint between panels to bind together the juxtaposed panels 750 and prevent adjacent panels from moving laterally with respect to each other to thereby maintain a uniform vertical alignment of an entire fence composed of a plurality of panels 750. In one embodiment, a steel plate measuring ¼″ thick, 1″ wide and 10″ long can, for example, be used. A 10″ long piece of number “4” rebar can also be used. In one embodiment, a groove is cut into the top of the juxtaposed panel. This groove is slightly larger in width and thickness and approximately one-half the length of the spanning plate or bar so that this plate or bar can be set into respective grooves of opposing panels 750 and then covered with adhesive mortar to both permanently secure and hide the plate or bar and also protect the plate or bar from rusting.

The columnless molded concrete wall panels of FIGS. 12, 14 and 15 can be constructed using the apparatus and methods described in Appendix A. Rebar 760 and coupling 765 can be inserted into the panel ends within this apparatus molding before the concrete is poured to form the wall panel using the apparatus described in Appendix A.

Another embodiment (not shown) of a columnless wall can be constructed by forming footings as shown at 590 in FIG. 17. Instead of rebar, two spaced vertical alignment steel pipes are inserted into the wet concrete. By way of specific example, 3″ round pipes or 3½″ square pipes having ¼″ thick walls can be typically used although pipes having other geometrical cross-sections can also be used.

The concrete wall sections 750 are fabricated so that the ends of each panel have a profile adapted to the shape of the pipe, e.g. either a semi-circular or rectangular profile to fit around the round or square pipe in the footing 750. In this embodiment, the wall sections are not required to be physically attached to the steel tubing, rather the panel is lowered onto the footings so that the respective profiles in opposite ends of the panel are received by the respective pipes to lock the opposing panels 750 into place against lateral movement. Thus, laterally, the pipes and wall profiles interlock. The walls are held vertically by gravity.

A jig is advantageously used to precisely locate the two vertical alignment steel pipes when they are inserted into the wet concrete. In one embodiment, the jig is a long angle iron whose length is determined by the length of the pre-cast concrete panel wall section 750. The angle iron has attached at opposite ends round or square hollow tubes. The spacing between these tubes conforms to the profile located at the opposite ends of the concrete panels. The interior diameter of the jig tubes is sized to fit over the ends of the lateral alignment steel pipes just after the pipes are vertically set in the wet concrete of the footing 790. As a result, the external alignment round or square pipes are precisely spaced to accept the profiled ends of the wall panel when it is later lowered onto the footings 790.

Pre-Cast Wall Erosion Control

A continuous line of concrete 780, as shown in FIGS. 16, 17, can be advantageously used to prevent erosion of the dirt beneath wall sections. The concrete barrier can also prevent animals from digging under a wall section. A trench 785 is first dug out between the column footings 790 and the footings and trench are filled with concrete. Unlike continuous footings used in block walls, the barrier of FIGS. 16, 17 is configured so that the wall panel does not rely on it for any structural support. The concrete footings 790 are advantageously constructed higher than the continuous line of concrete 780 so that the wall panels 400 do not touch the continuous line of concrete and a space is left between the two to allow for expansion. As discussed above, the wall panels are completely supported by the column footings 790 at each end. This is very beneficial because the wall panel is insulated from expansion or erosion of the soils beneath the wall panel. As a result, movement of the soil beneath the extended wall panel is not transferred to the wall panel so that cracks and other problems that commonly occur in block walls is avoided.

Column Caps

The tops of the manufactured and pour-in-place columns are typically finished by a decorative cap member 800. Lifting devices can be integrated into the column cap construction process so that a cap can be mechanically lifted by a crane either from the top or bottom of the cap. As shown in FIGS. 18, 19, a removable eye-bolt 810 can be installed into the top portion of the cap 800 as a top lifting device. In the bottom of the cap 800, a steel loop 815 can be installed for bottom lifting. The lower lifting loop 815 is then hidden inside the column when the cap 800 is installed on top of the column. With these devices installed, a cap 800 can be lifted out of the mold using one device, and then lifted onto a column using the other device. Installing the caps in this manner is quite beneficial because it improves safety while lifting the caps into position and lessens the amount of manual work. 

1. A column forming apparatus for forming concrete columns, comprising: a mold apparatus having a first forming piece, a second forming piece, a first blockout piece, and a second blockout piece, wherein the said first and second forming pieces are engaged with the said first and second blockout pieces, said first and second forming piece being substantially parallel and said first and second blockout pieces being substantially parallel; whereby a mixture can be poured into said mold apparatus to solidify and harden into a column structure of a predetermined shape with said two blockout pieces leaving indentations in the concrete column.
 2. The column forming apparatus of claim 1, further comprising external clamps placed at various locations whereby said clamps contain said forming pieces against the high pressures exerted by the poured liquid concrete used to form the columns.
 3. The column forming apparatus of claim 1, further comprising reinforcing means configured to be inserted into said mixture before said mixture is allowed to harden.
 4. The column forming apparatus of claim 1, further comprising a plug placed in the center of the mold, whereby a hole can be created through the center of the manufactured column so that said column can be secured to a footing with protruding rebar.
 5. The column forming apparatus of claim 1, further comprising a plurality of rebar pieces configured to be placed vertically within the mold and integrated into the finished column.
 6. The column forming apparatus of claim 1, wherein the bottom surface of the mold apparatus is supported on a surface of the mold apparatus is supported on a surface such as a rubber mat, hard ground, or solid concrete.
 7. The column forming apparatus of claim 1, further comprising a column cap.
 8. The column forming apparatus of claim 7, further comprising a removable eye-bolt configured to be installed at the top of said cap, whereby the cap can be lifted from the top.
 9. The column forming apparatus of claim 7, further comprising a steel loop configured to be installed at the bottom of said cap, whereby the cap can be lifted from the bottom.
 10. The column forming apparatus of claim 4, further comprising a column footing, comprising of an excavation filled with concrete.
 11. The column footing of claim 10, further comprising pieces of rebar protruding upward and configured to fit within the hole created by the plug.
 12. The column forming apparatus of claim 1 wherein said first and second molding pieces, when assembled, provide a substantially cylindrical shape for the outside of said column forming apparatus.
 13. The column forming apparatus of claim 2 wherein said external clamp comprise strap surrounding said first and second molding pieces.
 14. The column forming apparatus of claim 12 wherein said first and second molding pieces are made out of foam.
 15. The column forming apparatus of claim 14 wherein said foam is coated with a protective coating.
 16. The column forming apparatus of claim 1 comprising liners substantially covering the inner forces of said first and second molding pieces.
 17. The column forming apparatus of claim 16 wherein said liners substantially cover the interior exposed surface of said first and second molding pieces and provide a texture and shape for the column formed with the apparatus.
 18. The column forming apparatus of claim 1 wherein said blockout pieces include members respectively engaging said first and second forming pieces for holding said pieces together.
 19. The column forming apparatus of claim 16 wherein said liners have members respectively engaging said first and second forming pieces for holding said pieces together.
 20. The column forming apparatus for manufacturing concrete columns, comprising: a mold apparatus having a first side piece and a second side piece configured to form the poured concrete in a desired column shape; and wall panels placed between said first side piece and second side piece, whereby a column molded to the shapes of said wall panels can be constructed in situ as a part of a wall under construction.
 21. The column forming apparatus of claim 12, wherein the said side pieces are placed on both sides of the ends of juxtaposed positioned wall panels so that the ends of the panels extend into the mold and shape the sides of the column.
 22. The column forming apparatus of claim 12, further comprising pieces of cardboard or other sturdy material that are folded around the ends of said panels.
 23. The column forming apparatus of claim 12, further comprising clamps or braces on the side pieces to hold said side pieces together during the pouring and curing of the concrete.
 24. The column forming apparatus of claim 12, further comprising a free-standing panel support system for holding wall panels in place, comprising: a diagonal member that is staked into the ground at one end and supports the wall vertically; an L-shaped piece that fits snuggly against the side of the wall and is bent so that it extends under the wall panel and to the other side; and a turn-buckle apparatus that attaches said diagonal member to said L-shaped piece so that the position of the wall panel can be easily adjusted.
 25. The column forming apparatus of claim 12, further comprising a column cap.
 26. The column forming apparatus of claim 17, further comprising a removable eye-bolt configured to be installed at the top of said cap, whereby the cap can be lifted from the top.
 27. The column forming apparatus of claim 17, further comprising a steel loop configured to be installed at the bottom of said cap, whereby the cap can be lifted from the bottom.
 28. A method of manufacturing concrete columns, comprising: positioning a mold apparatus having a first forming piece, a second forming piece, a first blockout piece and a second blockout piece wherein the said first and second forming pieces are attached to the said first and second blockout pieces, said first and second forming pieces being substantially parallel and said first and second blockout pieces being substantially parallel, said two blockout pieces leave vertical recesses in the concrete column into which ends of wall panels can fit; introducing solidifying mixture into molding compartment; allowing said solidifying mixture to cure or harden to form a column; and removing said column from said mold apparatus after said solidifying mixture has sufficiently cured or hardened.
 29. The method of claim 20, wherein mold pieces are held together by external clamps placed at various locations in order to contain said blockout pieces and side pieces against the high pressures exerted by the poured liquid concrete used to form the columns.
 30. The method of claim 20, wherein a plug placed in the center of the mold.
 31. The method of claim 20, wherein a steel rebar a mesh kit in order to provide the column of added strength.
 32. The method of claim 23, wherein the rebar pieces are placed vertically within the mold and become integrated into the finished column.
 33. The method of claim 20, wherein the bottom surface of the mold apparatus is supported on a surface such as a rubber mat, hard ground, or solid concrete.
 34. A method of forming concrete columns, comprising: positioning between pre-fabricated wall panels a mold apparatus having a first side piece, a second side piece, wherein said first and second side pieces being substantially parallel; positioning said wall panels so that the ends of the panels extend into the mold and shape the sides of the column; introducing solidifying mixture into molding compartment in said mold apparatus; allowing said solidifying mixture to cure or harden to form said column; and removing said column from said mold apparatus after said solidifying mixture has sufficiently cured or hardened, whereby columns molded to the shapes of said wall panels can be constricted in situ as a part of wall under construction.
 35. The method of claim 26, further comprising placing reinforcing mechanism in the molding compartment before the introduction of solidifying mixture.
 36. The method of claim 27, wherein said reinforcing mechanism comprises of four pieces of long rebar.
 37. The method of claim 26, further comprising of means to tighten said mold apparatus around said wall panels.
 38. The method of claim 29, wherein the tightening means comprises of external clamps.
 39. The method of claim 26, further comprising support mechanisms on both sides of the wall panels.
 40. The method of claim 31, wherein said support mechanism comprises: a diagonal member that is staked into the ground at one end and supports the wall vertically; an L-shaped piece that fits snuggly against the side of the wall and is bent so that it extends under the wall panel and to the other side; and a turn-buckle apparatus that attaches said diagonal member to said L-shaped piece so that the position of the wall panel can be easily adjusted.
 41. A columnless wall, comprising: a first wall panel and a second wall panel; a continuous trench beneath said wall panels wherein said trench is filled with concrete; a plurality of support means that secures said wall panels to said continuous concrete-filled trench.
 42. The wall of claim 33, wherein said support means comprise of four pieces of rebar embedded vertically each said wall panel.
 43. The wall of claim 33, wherein said support means comprise of two larger pieces of rebar embedded vertically each said wall panel.
 44. The wall of claim 33, wherein said support means are attached to said trench by the use of threaded fittings having one end attached to a piece of threaded rebar and other end exposed at the bottom of a said wall panel.
 45. The wall of claim 33, further comprising means of holding said wall panels in proper position columnless wall construction.
 46. The wall of claim 37, wherein said means comprises of: a diagonal member that is staked into the ground at one end and supports the wall vertically; an L-shaped piece that fits snuggly against the side of the wall and is bent so that it extends under the wall panel and to the other side; and a turn-buckle apparatus that attaches said diagonal member to said L-shaped piece so that the position of the wall panel can be easily adjusted.
 47. A columnless wall, comprising wall panels where each wall panel is configured to have a molded tongue at one end and a corresponding molded groove at other end, whereby panels can be joined together by placing together two said wall panels and inserting the molded tongue if one said wall panel with the molded groove of another said wall panel.
 48. A columnless wall, comprising wall panels joined together by the use of a plate spanning cross the joint between juxtaposed said wall panels.
 49. The wall of claim 40, further comprising a groove having dimensions larger than said plate is cut into the top of said juxtaposed wall panels, whereby the plate can be laid in the grooves of juxtaposed panels and covered with adhesive mortar to both permanently secure and hide said plate and also to protect said plate from rusting.
 50. A method of joining wall panels together without the use if a column, comprising: providing said wall panels; molding a tongue structure and a corresponding groove structure in each said wall panel; positioning the said wall pieces together; and inserting the molded tongue of one said wall panel with the molded groove of another said wall panel.
 51. A method of joining wall panels together without the use of a column comprising: providing said wall panels; and placing a plate spanning cross the joint between juxtaposed said wall panels.
 52. The method of claim 43, further comprising molding a groove having dimensions larger than said plate is cut into the top of said juxtaposed wall panels, whereby the plate can be laid in the grooves of juxtaposed panels and covered with adhesive mortar to both permanently secure and hide said plate and also to protect said plate from rusting.
 53. A method of forming columnless wall, comprising: inserting vertical pipes into the ground with a predetermined spacing between said pipes; and fabricating wall panels to have profiles adapted to the shape of said pipes spaced at the said predetermined spacing between pipes, whereby each wall panel would have at least a plurality of profiles to fit around the pipes so that the wall panels can be held in position after said panels are lowered onto said vertical pipes.
 54. The method of claim 45, further comprising a jig to precisely measure the spacing between said pipes.
 55. The method of claim 46, wherein the jig is a long angle iron whose length is determined by the length of a pre-cast concrete panel wall section.
 56. A pre-cast wall erosion control system, comprising: a continuous line of concrete configures to prevent the erosion of the dirt beneath wall sections; and column footings configured to be constructed higher than the line of concrete so that wall panels do not touch the continuous line of concrete and a space is left between said panels and said line of concrete to allow for expansion of said wall panels. 